Ultrasensitive Wearable Strain Sensors based on a VACNT/PDMS Thin Film for a Wide Range of Human Motion Monitoring

Recent advances in smart wearable sensors for continuous human health monitoring

In recent years, the biochemical and biological research areas have shown great interest in a smart wearable sensor because of its increasing prevalence and high potential to monitor human health in a non-invasive manner by continuous screening of biomarkers dispersed throughout the biological analytes, as well as real-time diagnostic tools and time-sensitive information compared to conventional hospital-centered system. These smart wearable sensors offer an innovative option for evaluating and investigating human health by incorporating a portion of recent advances in technology and engineering that can enhance real-time point-of-care-testing capabilities. Smart wearable sensors have emerged progressively with a mixture of multiplexed biosensing, microfluidic sampling, and data acquisition systems incorporated with flexible substrate and bodily attachments for enhanced wearability, portability, and reliability. There is a good chance that smart wearable sensors will be relevant to the early detection and diagnosis of disease management and control. Therefore, pioneering smart wearable sensors into reality seems extremely promising despite possible challenges in this cutting-edge technology for a better future in the healthcare domain. This review presents critical viewpoints on recent developments in wearable sensors in the upcoming smart digital health monitoring in real-time scenarios. In addition, there have been proactive discussions in recent years on materials selection, design optimization, efficient fabrication tools, and data processing units, as well as their continuous monitoring and tracking strategy with system-level integration such as internet-of-things, cyber-physical systems, and machine learning algorithms.

Prototyping a wearable and stretchable graphene-on-PDMS sensor for strain detection on human body physiological and joint movements

In the era of wearable electronic devices, which are quite popular nowadays, our research is focused on flexible as well as stretchable strain sensors, which are gaining humongous popularity because of recent advances in nanocomposites and their microstructures. Sensors that are stretchable and flexible based on graphene can be a prospective 'gateway' over the considerable biomedical speciality. The scientific community still faces a great problem in developing versatile and user-friendly graphene-based wearable strain sensors that satisfy the prerequisites of susceptible, ample range of sensing, and recoverable structural deformations. In this paper, we report the fabrication, development, detailed experimental analysis and electronic interfacing of a robust but simple PDMS/graphene/PDMS (PGP) multilayer strain sensor by drop casting conductive graphene ink as the sensing material onto a PDMS substrate. Electrochemical exfoliation of graphite leads to the production of abundant, fast and economical graphene. The PGP sensor selective to strain has a broad strain range of ⁓60%, with a maximum gauge factor of 850, detection of human physiological motion and personalized health monitoring, and the versatility to detect stretching with great sensitivity, recovery and repeatability. Additionally, recoverable structural deformation is demonstrated by the PGP strain sensors, and the sensor response is quite rapid for various ranges of frequency disturbances. The structural designation of graphene's overlap and crack structure is responsible for the resistance variations that give rise to the remarkable strain detection properties of this sensor. The comprehensive detection of resistance change resulting from different human body joints and physiological movements demonstrates that the PGP strain sensor is an effective choice for advanced biomedical and therapeutic electronic device utility.

Vibration Sensors on Flexible Substrates Based on Nanoparticle Films Grown by Physical Vapor Deposition

Flexible electronics have gained a lot of attention in recent years due to their compatibility with soft robotics, artificial arms, and many other applications. Meanwhile, the detection of acoustic frequencies is a very useful tool for applications ranging from voice recognition to machine condition monitoring. In this work, the dynamic response of Pt nanoparticles (Pt NPs)-based strain sensors on flexible substrates is investigated. the nanoparticles were grown in a vacuum by magnetron-sputtering inert-gas condensation. Nanoparticle sensors made on cracked alumina deposited by atomic layer deposition on the flexible substrate and reference nanoparticle sensors, without the alumina layer, were first characterized by their response to strain. The sensors were then characterized by their dynamic response to acoustic frequency vibrations between 20 Hz and 6250 Hz. The results show that alumina sensors outperformed the reference sensors in terms of voltage amplitude. Sensors on the alumina layer could accurately detect frequencies up to 6250 Hz, compared with the reference sensors, which were sensitive to frequencies up to 4250 Hz, while they could distinguish between two neighboring frequencies with a difference of no more than 2 Hz.

Anisotropic Piezoresistive Sensors Made with Magnetically Induced Vertically Aligned Carbon Nanotubes/Polydimethylsiloxane

A piezoresistive material consisting of internal vertically aligned carbon nanotubes acting in concert with an external microdome structure is prepared to obtain a flexible piezoresistive sensor with high anisotropy. Here, we first obtained flexible piezoresistive composites (VCP) with anisotropic properties by inducing the vertical alignment of multiwalled carbon nanotubes in the pressure direction under a weak magnetic field of 0.6 T. Then, the composite with a microdome structure on the surface (m-VCP) was fabricated by a mold with a microstructure to further increase the anisotropy of the composite. The m-VCP microstructure was docked with VCP and placed between two layers of copper foil. With the synergistic effect of vertically aligned carbon nanotubes and the microdome structure, the sensitivity of the flexible sensor in the pressure direction was dramatically increased. In the low-strain range (0-6%), the sensitivity of m-VCP (GF = 9.208) is improved by 49% compared to m-CP and by 86% compared to VCP. The sensor has high anisotropy in the piezoresistive direction and retains good fatigue resistance under fatigue testing for 2000 cycles. This means that the sensor can be used in emerging fields such as human health monitoring, wearable electronics, and intelligent human-computer interaction.

Manipulator Control System Based on Flexible Sensor Technology

The research on the remote control of manipulators based on flexible sensor technology is gradually extensive. In order to achieve stable, accurate, and efficient control of the manipulator, it is necessary to reasonably design the structure of the sensor with excellent tensile strength and flexibility. The acquisition of manual information by high-performance sensors is the basis of manipulator control. This paper starts with the manufacturing of materials of the flexible sensor for the manipulator, introduces the substrate, sensor, and flexible electrode materials, respectively, and summarizes the performance of different flexible sensors. From the perspective of manufacturing, it introduces their basic principles and compares their advantages and disadvantages. Then, according to the different ways of wearing, the two control methods of data glove control and surface EMG control are respectively introduced, the principle, control process, and detection accuracy are summarized, and the problems of material microstructure, reducing the cost, optimizing the circuit design and so on are emphasized in this field. Finally, the commercial application in this field is explained and the future research direction is proposed from two aspects: how to ensure real-time control and better receive the feedback signal from the manipulator.

Research status of polysiloxane-based piezoresistive flexible human electronic sensors

Flexible human body electronic sensor is a multifunctional electronic device with flexibility, extensibility, and responsiveness. Piezoresistive flexible human body electronic sensor has attracted the extensive attention of researchers because of its simple preparation process, high detection sensitivity, wide detection range, and low power consumption. However, the wearability and affinity to the human body of traditional flexible human electronic sensors are poor, while polysiloxane materials can be mixed with other electronic materials and have good affinity toward the human body. Therefore, polysiloxane materials have become the first choice of flexible matrixes. In this study, the research progress and preparation methods of piezoresistive flexible human electronic sensors based on polysiloxane materials in recent years are summarized, the challenges faced in the development of piezoresistive flexible human electronic sensors are analyzed, and the future research directions are prospected.

Direct fabrication of flexible tensile sensors enabled by polariton energy transfer based on graphene nanosheet films

A fundamental problem in the direct manufacturing of flexible devices is the low melting temperature of flexible substrates, which hinders the development of flexible electronics. Proposed here is an electron-cyclotron-resonance sputtering system that can batch-fabricate devices directly on flexible substrates under a low temperature by virtue of the polariton energy transfer between the plasma and the material. Flexible graphene nanosheet-embedded carbon (F-GNEC) films are manufactured directly on polyimide, polyethylene terephthalate, and polydimethylsiloxane, and how the substrate bias (electron energy), microwave power (plasma flux and energy), and magnetic field (electron flux) affect the nanostructure of the F-GNEC films is investigated, indicating that electron energy and flux contribute to the formation of standing graphene nanosheets in the film. The films have good uniformity of distribution in a large size (17 mm × 17 mm), and tensile and angle sensors with a high gauge factor (0.92) and fast response (50 ms) for a machine hand are obtained by virtue of the unique nanostructure of the F-GNEC film. This work sheds light on the quantum manufacturing of carbon sensors and its applications for intelligent machine hands and virtual-reality technology.

Preparation and Performance of AgNWs/PDMS Film-Based Flexible Strain Sensor

Flexible strain sensors are widely used in the fields of personal electronic equipment and health monitoring to promote the rapid development of modern social science and technology. In this paper, silver nanowires (AgNWs) prepared via the polyol reduction method were used to construct a flexible strain sensor. The AgNWs/PDMS film was obtained by transfer printing using AgNWs as a conductive layer and polydimethylsiloxane (PDMS) as a flexible substrate. The morphology of AgNWs was characterized by SEM and TEM. The aspect ratio of the AgNWs was more than 700. The strain sensitivity factor of the sensor was 2.8757, with a good linear relationship between the resistance and the strain. Moreover, the strain sensor showed good response results in human activity monitoring and the LED lamp response test, which provides a new idea for the construction of flexible wearable devices.

Fabrication of vertically aligned CNT- vanadium oxide hybrid architecture with enhanced compressibility and supercapacitor performance

The demand for energy storage devices in wearable electronics effectuates a requisition for compressible and flexible supercapacitors with high performance and mechanical reliability. We report the fabrication of vanadium oxide hybrid with VACNT and its electrochemical supercapacitor performance along with the compression response. Compressive modulus of 730 ± 40 kPa is obtained for bare VACNT forest whereas its hybrid with vanadium oxide shows a compressive modulus of 240 ± 60 kPa. Controlled CVD process enabled the formation of porous CNT architecture coated with vanadium oxide particles due to the simultaneous reduction of V₂O₅and partial oxidation of CNT forest. Vanadium oxide decorated on vertically aligned carbon nanotubes acts as the active material for supercapacitor applications. A 17 folds increase in areal capacitance and 36 folds increase in volumetric capacitance are observed on depositing vanadium oxide particles on the VACNT forest. High coulombic efficiency of 97.8% is attained even after 10 000 charge-discharge cycles indicating the high stability of the hybrid.

An Ultra-Sensitive and Multifunctional Electronic Skin with Synergetic Network of Graphene and CNT

Electronic skin (e-skin) has attracted tremendous interest due to its diverse potential applications, including in physiological signal detection, health monitoring, and artificial throats. However, the major drawbacks of traditional e-skin are the weak adhesion of substrates, incompatibility between sensitivity and stretchability, and its single function. These shortcomings limit the application of e-skin and increase the complexity of its multifunctional integration. Herein, the synergistic network of crosslinked SWCNTs within and between multilayered graphene layers was directly drip coated onto the PU thin film with self-adhesion to fabricate versatile e-skin. The excellent mechanical properties of prepared e-skin arise from the sufficient conductive paths guaranteed by SWCNTs in small and large deformation under various strains. The prepared e-skin exhibits a low detection limit, as small as 0.5% strain, and compatibility between sensitivity and stretchability with a gauge factor (GF) of 964 at a strain of 0-30%, and 2743 at a strain of 30-60%. In physiological signals detection application, the e-skin demonstrates the detection of subtle motions, such as artery pulse and blinking, as well as large body motions, such as knee joint bending, elbow movement, and neck movement. In artificial throat application, the e-skin integrates sound recognition and sound emitting and shows clear and distinct responses between different throat muscle movements and different words for sound signal acquisition and recognition, in conjunction with superior sound emission performance with a sound spectrum response of 71 dB (f = 12.5 kHz). Overall, the presented comprehensive study of novel materials, structures, properties, and mechanisms offers promising potential in physiological signals detection and artificial throat applications.

Carbon dioxide-boosted growth of high-density and vertically aligned carbon nanotube arrays on a stainless steel mesh

Vertically aligned carbon nanotubes (VACNTs), a unique group of highly aligned CNTs normal to a substrate, have been extensively studied during the past decades. However, it is a long-standing challenge to improve the height of VACNTs due to the incidental deactivation of catalysts during growth. Herein, we demonstrate a facile strategy toward synthesizing high-density and well-aligned CNT arrays from in situ formed Fe-based catalysts on a stainless steel (SS) mesh. These catalysts were generated by direct oxidation-reduction treatment to the SS, which had excellent adhesion on the mesh substrate, and thus suppressed catalyst aggregation and promoted CNT growth under the flow of C₂H₂. In particular, by feeding additional CO₂ at an optimal rate, the height of CNT arrays could be boosted from ca. 15 μm to ca. 80.0 μm, one of the highest heights observed for VACNTs on SS-based substrates so far. This is attributed to the prolonged activity of the catalysts by CO₂ induced removal of extra carbon. Our study might provide an insight into the development of efficient strategies for VACNT growth on conductive substrates.

Temperature Dependence of Electrical Resistance in Carbon Nanotube Composite Film during Curing Process

Carbon nanotube (CNT) film possesses excellent mechanical and piezoresistivity, which may act as a sensor for process monitoring and reinforcement of the final composite. This paper prepared CNT/epoxy composite film via the solution dipping method and investigated the electrical resistance variation (ΔR/R₀) of CNT/epoxy composite film during the curing process. The temperature dependence of electrical resistance was found to be closely related to resin rheological properties, thermal expansion, and curing shrinkage. The results show that two opposing effects on electrical resistivity occur at the initial heating stage, including thermal expansion and condensation caused by the wetting tension of the liquid resin. The lower resin content causes more apparent secondary impregnation and electrical resistivity change. When the resin viscosity remains steady during the heating stage, the electrical resistance increases with an increase in temperature due to thermal expansion. Approaching gel time, the electrical resistance drops due to the crosslink shrinkage of epoxy resin. The internal stress caused by curing shrinkage at the high-temperature platform results in an increase in electrical resistance. The temperature coefficient of resistance becomes larger with an increase in resin content. At the isothermal stage, an increase in ΔR/R₀ value becomes less obvious with a decrease in resin content, and ΔR/R₀ even shows a decreasing tendency.

High-Performance Strain Sensors Based on Au/Graphene Composite Films with Hierarchical Cracks for Wide Linear-Range Motion Monitoring

Stretchable strain sensors based on nanomaterial thin films have aroused extensive interest for the strain perception of smart skins. However, it still remains challenging to have them achieve high sensitivity over wide linear working ranges. Herein, we propose a facile strategy to fabricate stretchable strain sensors based on Au/graphene composite films (AGCFs) with hierarchical cracks and demonstrate their superior sensing performances. The polydimethylsiloxane substrates were covered with self-assembled graphene films (SAGFs) and sputtered with Au, and then prestretching was applied to introduce hierarchical cracks. The AGCF strain sensors exhibited high sensitivity (gauge factor (GF) ≈ 153) and favorable linearity (R² ≈ 0.9975) in the wide working range (0-20%) with ultralow overshooting (∼1.7% at 20%), fast response (<42.5 ms), and also excellent cycling stability (1500 cycles). Besides, these patternable sensors could further achieve higher GF (∼320) via pattern designing. The dominant effect of the intermediate wrinkled SAGFs in forming hierarchical cracks was studied, and the linear sensing mechanism of the as-formed fractal microstructures was also revealed in detail. Moreover, the AGCF strain sensors were tested for motion monitoring of the human body and electronic bird. Due to the remarkable versatility, scalable fabrication, and integration capability, these sensors demonstrate great potential to construct smart skins.

Electrospun Elastic Films Containing AgNW-Bridged MXene Networks as Capacitive Electronic Skins

Electronic skins (e-skins) are increasingly investigated and applied in wearable devices, but the robustness and convenient production of traditional e-skins are restricted. In this work, electrospun sandwich-structured elastic films (ESEFs) are developed and utilized as capacitive e-skins. The ESEFs consist of two nanocomposite mats as the electrode layers and a sandwiched thermoplastic polyurethane (TPU) mat as the dielectric layer. The nanocomposite mats are composed of thermoplastic polyurethane (TPU) and AgNW-bridged MXene (AgNW, silver nanowire; MXene, Ti₃C₂T_x) conductive network. The resulting ESEFs achieve a tensile strength of 14.80 MPa, an elongation at break of 270%, and an outstanding antifatigue property. E-skins of such ESEFs have the ability to respond to both strain and pressure with a high gauge factor (GF) (strain: GF = 1.21; pressure: GF = 0.029 kPa^-1), wide response range (strain: 0-150%; pressure: 0-70 kPa), low response time, and outstanding stability (2000 cycles). On the basis of integrated sensing performances, such e-skins are further applied in monitoring various mechanical stimuli in daily life, including bending of a plastic plate, joint bending, and swallowing.

Human Skin-Inspired Electrospun Patterned Robust Strain-Insensitive Pressure Sensors and Wearable Flexible Light-Emitting Diodes

Wearable skin-inspired electronic skins present remarkable outgrowth in recent years because their promising comfort device integration, lightweight, and mechanically robust durable characteristics led to significant progresses in wearable sensors and optoelectronics. Wearable electronic devices demand real-time applicability and factors such as complex fabrication steps, manufacturing cost, and reliable and durable performances, severely limiting the utilization. Herein, we nominate a scalable solution-processable electrospun patterned candidate capable of forming ultralong mechanically robust nano-microdimensional fibers with higher uniformity. Nanofibrous patterned substrates present surface energy and silver nanoparticle crystallization shifts, contributing to strain-sensitive and -insensitive conductive electrodes (10 000 cycles of 50% strain). Synergistic robust stress releasing and durable electromechanical behavior engenders stretchable durable health sensors, strain-insensitive pressure sensors (sensitivity of ∼83 kPa^-1 and 5000 durable cycles), robust alternating current electroluminescent displays, and flexible organic light-emitting diodes (20% improved luminescence and 300 flex endurance of 2 mm bend radius).

Vertically Aligned Carbon Nanotubes as a Unique Material for Biomedical Applications

Vertically aligned carbon nanotubes (VACNTs), a unique classification of CNT, highly oriented and normal to the respective substrate, have been heavily researched over the last two decades. Unlike randomly oriented CNT, VACNTs have demonstrated numerous advantages making it an extremely desirable nanomaterial for many biomedical applications. These advantages include better spatial uniformity, increased surface area, greater susceptibility to functionalization, improved electrocatalytic activity, faster electron transfer, higher resolution in sensing, and more. This Review discusses VACNT and its utilization in biomedical applications particularly for sensing, biomolecule filtration systems, cell stimulation, regenerative medicine, drug delivery, and bacteria inhibition. Furthermore, comparisons are made between VACNT and its traditionally nonaligned, randomly oriented counterpart. Thus, we aim to provide a better understanding of VACNT and its potential applications within the community and encourage its utilization in the future.

Ultrasensitive and highly stretchable fibers with dual conductive microstructural sheaths for human motion and micro vibration sensing

Conductive and stretchable fibers are important components of the increasingly popular wearable electronic devices as they meet the design requirements of excellent electrical conductivity, stretchability, and wearability. In this work, we developed a novel dual conductive-sheath fiber (DCSF) with a conductive sheath composed of a porous elastic conductive layer and cracked metal networks, thus achieving ultrahigh sensitivity under a large strain range. The core of the DCSF is made of thermoplastic polyurethane (TPU) elastic fiber wrapped in a porous stretchable conductive layer composed of carbon nanotubes (CNTs) and TPU. Next, a layer of gold film is deposited on the surface of the porous stretchable conductive layer by ion beam sputtering. Due to the fast response time of 184 ms and ultrahigh sensitivity in the 0-100% strain range (a gauge factor of 184.50 for a strain of 0-10%, 4.12 × 10⁵ for 10%-30%, and 2.80 × 10⁵ for 30%-100%) of the DCSF strain sensor, we successfully wove the fiber strain sensor into gloves and could realize the recognition of different hand gestures. Also the DCSF strain sensor can be applied to detect microvibrations efficiently. The demonstrated DCSF has potential applications in the development of smart wearable devices and micro vibration sensors.

Inherently Conductive Poly(dimethylsiloxane) Elastomers Synergistically Mediated by Nanocellulose/Carbon Nanotube Nanohybrids toward Highly Sensitive, Stretchable, and Durable Strain Sensors

With the rapid development of soft electronics, flexible and stretchable strain sensors are highly desirable. However, coupling of high sensitivity and stretchability in a single strain sensor remains a challenge. Herein, a kind of conductive elastomer is constructed with poly(dimethylsiloxane) (PDMS) and silylated cellulose nanocrystal (SCNC)/carbon nanotube (CNT) nanohybrids through a facile one-pot solution-casting method. The hydrophobic SCNCs can effectively facilitate the dispersion of CNTs in PDMS and synergistically improve the interfacial compatibility between CNTs and the PDMS matrix, resulting in favorable stress and electron transfer in the polymer network. Due to the outstanding electrical conductivity of CNTs and the excellent dispersity and high mechanical performance of SCNCs, combined with the good compatibility between SCNC-mediated carbon nanotubes (SCNC-CNTs) and PDMS, the resulting composite elastomer (SCNC-CNT/PDMS) shows high electrical conductivity (∼2.77 S m^-1), tensile strength (∼5.72 MPa), and fatigue resistance properties. The strain sensor assembled by SCNC-CNT/PDMS demonstrates a high strain range above 100%, appealing strain sensitivity with a gauge factor of 37.11 at 50-100% strain, and long-term stability and durability, which is capable of monitoring both real-time human motions and acoustic vibrations. This work paves a new way for the design and controllable preparation of flexible and stretchable conductive elastomers, demonstrating promising applications in wearable devices and intelligent electronics.